Senior Process Development Engineer – Pyrolyse-Test (m/w/d)

Job Description

Our mission is to return the atmosphere to 280 ppm CO???. We convert excess inedible biomass into carbon-rich bio-oil and inject it into underground storage for permanent carbon removal. At scale, we can use bio-oil to make fossil-free iron.

Our carbon removal efforts began in 2020 with initial purchases from customers like Stripe, Shopify, and Microsoft. Since then, we've scaled to thousands of tons of carbon removal, grown to over a hundred employees, and established three locations in San Francisco, Colorado, and Louisiana.

We're expanding our team of ambitious, creative, and hands-on problem solvers. We value psychological safety, collaboration, and continuous learning. We take calculated risks and treat mistakes as opportunities to improve. If you're excited about tackling big challenges, we encourage you to explore our company values.

Come help us reverse climate change. Gigatons or bust!

About the Role

We're looking for a Senior Process Development Engineer to join our Pyrolysis Test Engineering team. Reporting to the Director of Pyrolysis, you will lead the development and scale-up of next-generation biomass conversion processes from pilot testing through commercial deployment. You will define experimental strategy, drive resolution of complex scale-up challenges, and provide technical leadership across R&D, Engineering, and Operations teams.

This role requires deep process engineering expertise, strong technical judgment, and the ability to translate ambiguous experimental findings into robust, scalable industrial processes.

Your Responsibilities

• Lead development of next-generation Charm pyrolyzers and biomass conversion processes to maximize bio-oil yield, product quality, reliability, and economic performance.
• Define test plans and experimental campaigns that address critical technical uncertainties and inform commercialization decisions.
• Own investigation and resolution of complex process performance, operability, and scale-up challenges across pilot and demonstration systems.
• Develop and validate process models, material and energy balances, and engineering analyses to guide process improvements and future facility design.
• Lead interpretation and communication of experimental results to technical and non-technical stakeholders, including recommendations for strategic development priorities.
• Prepare and review process engineering documentation including Process Flow Diagrams (PFDs), Piping and Instrumentation Diagrams (P&IDs), Process Control Narratives (PCNs), Standard Operating Procedures (SOPs), and process equipment specifications.
• Lead or facilitate process safety activities including Hazard and Operability study (HAZOP), Failure Mode and Effects Analysis (FMEA), Management of Change (MOC) reviews, and commissioning/startup readiness reviews.
• Partner closely with Mechanical, Automation, Electrical, Manufacturing, and Operations teams to ensure successful deployment and operation of new process technologies.
• Mentor junior engineers and contribute to the development of engineering standards, best practices, and technical culture across the organization.
• Support our 24/7 operations through a rotating after-hours coverage schedule, totaling approximately 2-3 weeks per year.

You Bring

• Bachelor's degree in Chemical Engineering, Mechanical Engineering, or a related field.
• 7+ years of experience in process development engineering, or scale-up engineering, including significant experience operating and developing pilot-scale systems.
• Demonstrated success scaling chemical, thermochemical, energy, or industrial process technologies from pilot through commercial deployment.
• Deep understanding of heat transfer, reaction engineering, mass and energy balances, process controls, process safety, and industrial operations.
• Strong hands-on troubleshooting skills and the ability to diagnose complex process and equipment failures in ambiguous environments.
• Experience leading cross-functional technical projects involving multiple engineering disciplines.
• Excellent written and verbal communication skills, including the ability to influence technical direction and align diverse stakeholders.
• Strong engineering judgment and ability to balance technical rigor, operational realities, schedule, and cost.
• Excitement for scaling industrial technologies that can meaningfully impact climate change.

Bonus if you Bring

• M.S. or Ph.D. in Chemical Engineering, Mechanical Engineering, or a related field.
• Experience with pyrolysis, gasification, biomass conversion, refining, petrochemicals, renewable fuels, or other thermochemical processing technologies.
• Experience commissioning and operating industrial process systems at demonstration or commercial scale.
• Experience leading process hazard analyses and implementing process safety management programs.
• Experience managing external engineering partners, equipment vendors, or contract manufacturers.

$98,400 - $147,600 a year

What We Offer

• Equity ownership through stock options
• 100% employee healthcare premiums covered
• Comprehensive medical, dental, and vision coverage with multiple plan options
• Employer-funded HSA contributions for eligible HDHP plans
• Traditional and Roth 401(k) with a 50% match on contributions up to 6%
• Paid leave, including parental and medical leave
• PPE and workwear allowances
• Annual professional development stipend
• Employee recognition programs that celebrate impactful work and team contributions
• Opportunities for internal growth, career development, and transition into climate from a range of industries and backgrounds

Visa Sponsorship Policy

Since we are a small startup, certain accommodations for visa sponsorship may not be within our capability. At this time, Charm Industrial is only sponsoring E3 and TN visas.

Our Commitment

Charm Industrial is an equal opportunity employer. We hire based on skills, experience, and passion for our mission. Climate challenges require a wide range of perspectives and expertise, and we welcome applicants from all backgrounds. We're excited to grow our team with people who bring unique strengths and help us improve as a company.

At Charm, we may use AI-enabled tools to support certain aspects of the hiring process, including organizing candidate information and highlighting experience that may be relevant to a particular role. In a world where AI-assisted resumes, synthetic content, and deepfakes are increasingly common, these tools help our team navigate the process thoughtfully and efficiently. Every application and resume is reviewed by a member of our hiring team, and hiring decisions are made by people, not algorithms. Our recruiting process is designed to ensure candidates are evaluated fairly, consistently, and in alignment with our equal employment opportunity commitments. AI tools support our team's work, but they do not replace human judgment or determine hiring outcomes.